System and method for maintaining a minimum separation between pallets positioned on adjacent racks

ABSTRACT

A system for maintaining a minimum separation between pallets positioned on racks. The system comprising a double back stop. The stop includes: a first and a second back stop configured to prevent lateral movement of the pallets beyond the back stops, the back stops defining a minimum separation between the pallets; and a middle section connecting the back stops includes a vertical cross-member; and one or more of the following: a clip forming a channel affixed to the double back stop, and/or a web affixed to the double back stop, and/or member affixed to the double back stop, and/or a slot in the double back stop.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation-In-Part of and claims the benefit toco-pending U.S. Ser. No. 14/324,840 filed Jul. 7, 2014 which claims thebenefit of U.S. Provisional Patent Application No. 61/843,538, filedJul. 8, 2013, both of which are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to racks for mounting pallets, and moreparticularly, to a system and method for maintaining a minimumseparation between pallets mounted on adjacent racks.

BACKGROUND OF THE INVENTION

Pallets are flat transport structures that support goods in a stablefashion as the pallet is lifted by a jacking device such as a forklift,for example. A pallet is the structural foundation of a unit load thatenhances handling and storage efficiencies. Goods or shipping containersare often placed on a pallet and secured with strapping, stretch wrap orshrink wrap and then subsequently shipped. While most pallets are madeof wood, pallets may also be made from plastic and metal material.

In a warehouse environment, pallets are routinely stored on racks whichpermit the pallets to be stacked on top of one another in a column form.The racks are typically spaced apart from one another by a sufficientdistance, so that stacked pallets on one rack can overhang the rack andstill maintain a separation from stacked pallets that overhang anadjacent rack. For safety reasons, various insurance and/or legalregulations require a minimum separation between the stacked pallets onadjacent racks. For example, in the event of a fire in the warehouse,these minimum separation regulations may facilitate water coverage fromoverhead sprinkler systems between the stacked pallets. The minimumseparation regulations may depend on the specific insurance and/or legalregulations.

Various conventional approaches have been proposed to provide aseparation between the stacked pallets on adjacent racks, in order tocomply with these insurance and/or legal regulations. FIG. 1 illustratesone such approach including a Z-stop bracket 110 to attempt to provide aseparation 118 between a first pallet 113 positioned on a first rack 112and a second pallet 115 positioned on a second rack 114. As illustratedin FIG. 1, the Z-stop bracket 110 is attached to the first rack 112using an attachment means 116, such as bolts, for example. The firstpallet 113 overhangs the first rack 112 and engages the Z-stop bracket110 in an effort to maintain the separation 118. An additional Z-stopbracket (not shown) may be attached to the second rack 114 in a similarmanner as the Z-stop bracket 110 attached to the first rack 112, toengage the second pallet 115 and maintain the separation 118.

BRIEF DESCRIPTION OF THE INVENTION

A system for maintaining a minimum separation between pallets positionedon racks. The system comprising a double back stop. The stop includes: afirst and a second back stop configured to prevent lateral movement ofthe pallets beyond the back stops, the back stops defining a minimumseparation between the pallets; and a middle section connecting the backstops includes a vertical cross-member; and one or more of thefollowing: a clip forming a channel affixed to the double back stop,and/or a web affixed to the double back stop, and/or member affixed tothe double back stop, and/or a slot in the double back stop.

BRIEF DESCRIPTION OF THE DRAWINGS

A more particular description of the invention briefly described abovewill be rendered by reference to specific embodiments thereof that areillustrated in the appended drawings. Understanding that these drawingsdepict only typical embodiments of the invention and are not thereforeto be considered to be limiting of its scope, the embodiments of theinvention will be described and explained with additional specificityand detail through the use of the accompanying drawings in which:

FIG. 1 is an end view of an exemplary embodiment of a conventionalZ-stop bracket attached to a rack to engage a pallet positioned on therack;

FIG. 2 is a perspective view of an exemplary embodiment of a system formaintaining a minimum separation between a first pallet positioned on afirst rack and a second pallet positioned on a second rack according tothe present invention;

FIG. 3 is a bottom perspective view of the system of FIG. 2;

FIG. 4 is a perspective view of the system of FIG. 2 without the firstand second pallets positioned on the first and second racks;

FIG. 5 is a perspective view of an exemplary embodiment of the doubleback stop of the system of FIG. 2;

FIG. 6 is a front perspective view of the double back stop of FIG. 5;

FIG. 7 is a side perspective view of the double back stop of FIG. 5;

FIG. 8 is a front view of the double back stop of FIG. 5;

FIG. 9 is a top perspective view of an alternate embodiment of thedouble back stop of the system of FIG. 2;

FIG. 10 is a flowchart illustrating an exemplary embodiment of a methodfor forming the double back of FIG. 2; and

FIG. 11 is a flowchart illustrating an exemplary embodiment of a methodfor maintaining a minimum separation between a first pallet positionedon a first rack and a second pallet positioned on a second rack.

FIGS. 12-14 illustrate an alternate embodiment of the invention with aclip forming a channel for receipt of the rack.

FIG. 15 illustrates an alternate embodiment of the invention with a web.

FIG. 16 illustrates an alternate embodiment of the invention with amember (i.e., a combination of the clip and the web).

FIG. 17 illustrates an alternate embodiment of the invention with aslot.

DETAILED DESCRIPTION OF THE INVENTION

In describing particular features of different embodiments of thepresent invention, number references will be utilized in relation to thefigures accompanying the specification. Similar or identical numberreferences in different figures may be utilized to indicate similar oridentical components among different embodiments of the presentinvention.

The inventor of the present invention recognized that the conventionalapproaches to attempt to maintain a separation between the pallets onadjacent racks have several drawbacks. For example, the inventor of thepresent invention recognized that the installation process for securingthe Z-stop bracket 110 to the rack 112 of FIG. 1 is cumbersome,requiring extensive attachment means, such as multiple through bolts.Thus, the inventor proposed the system described herein, which includesa double back stop that involves minimal installation steps, to attachto adjacent racks and maintain a minimum separation between palletspositioned on the adjacent racks.

Additionally, the inventor of the present invention recognized that theZ-stop bracket 110 is inherently weak relative to typical lateral loadsimposed by the pallets 113, 115 and thus frequently bends during use,thereby failing to maintain the separation 118 between the pallets 113,115. Thus, the inventor proposed the system with the double back stopdescribed herein, which maintains structural integrity in the presenceof typical lateral loads imposed by pallets 113, 115 and thus maintainsa minimum separation between pallets positioned on adjacent racks.

FIGS. 2-3 illustrate a system 10 for maintaining a minimum separation 12between a first pallet 14 positioned on a first rack 16 and a secondpallet 18 positioned on a second rack 20. A double back stop 22 isattached to the first rack 16 and the second rack 20, to maintain theminimum separation 12 between the first pallet 14 and the second pallet18. For purposes of clarity, FIG. 2 omits the second pallet 18 so thatthe double back stop 22 is visible between the first and second racks16, 20. FIG. 3 illustrates the second pallet 18 positioned on the secondrack 20 and the minimum separation 12 maintained between the first andsecond pallets 14, 18 by the double back stop 22. In an exemplaryembodiment, the minimum separation 12 may be selected based on one ormore insurance and/or legal regulations. In another exemplaryembodiment, the minimum separation 12 may be selected within a range of5-7 inches, such as 6 inches, for example. However, the embodiments ofthe system 10 and the double back stop 22 are not limited to anyspecific range of minimum separation 12 and may be employed to maintainany minimum separation between pallets positioned on adjacent racks.

As further illustrated in FIGS. 2-3, the double back stop 22 includes afirst back stop 24 attached to the first rack 16 to prevent lateralmovement of the first pallet 14 beyond the first back stop 24. Thedouble back stop 22 depicted in FIGS. 2-3 also includes a second backstop 26 attached to the second rack 20 to prevent lateral movement ofthe second pallet 18 beyond the second back stop 26. As illustrated inFIG. 3, a minimum distance 25 is maintained between the first backstop24 and the second backstop 26, so that the minimum separation 12 ismaintained between the first and second pallets 14, 18. In an exemplaryembodiment, the minimum distance 25 is approximately equal to theminimum separation 12. However, the minimum distance 25 may be less thanthe minimum separation 12, provided that the minimum separation 12 ismaintained between the pallets 14, 18. FIGS. 2-3 further illustrate thatthe minimum distance 25 between the first and second backstops 24, 26 ismaintained by a middle section 28 connecting the first back stop 24 tothe second back stop 26 such that the first back stop 24 and the secondback stop 26 are spaced apart by the minimum distance 25. As illustratedin FIG. 3, a length of the middle section 28 between the first back stop24 and the second back stop 26 is the minimum distance 25.

FIG. 4 illustrates the system 10 without the first and second pallets14, 18 positioned on the first and second racks 16, 20. As shown in FIG.4, the first and second racks 16, 20 include a grating 58 that extendsacross a top of the first and second racks 16, 20 and over an outersurface 66 of a side 60 of the first and second racks 16, 20. However,the grating 58 does not extend beyond the outer surface 66 of the side60 of the first and second racks 16, 20 at attachment locations 62, 64along the first and second racks 16, 20, where the first and second backstops 24, 26 are attached to the side 60 of the first and second rack16, 20. As further illustrated in FIG. 4, the first and second back stop24, 26 attach to the racks 16, 20 by extending over an inner surface 68of the side 60 of the first and second side racks 16, 20 to theattachment locations 62, 64. The first and second racks 16, 20 and thegrating 58 structural arrangement of FIG. 4 is merely one exemplaryembodiment of a pair of racks that can be used with the double back stop22 of the present invention. Indeed, the embodiments of the double backstop 22 discussed herein may be used to maintain the minimum separation12 between pallets positioned on any pair of adjacent racks constructedfrom any structural components.

FIG. 5 illustrates the double back stop 22 that is attached to the firstand second racks 16, 20 of the system 10 discussed above. The doubleback stop 22 includes the first back stop 24 discussed above whichincludes a first horizontal member 30 configured to extend across a topof the first rack 16. The first back stop 24 also includes a first backstop member 38 to extend upward from the first horizontal member 30 by aheight 42 to prevent lateral movement of the first pallet 14 beyond thefirst back stop 24. In an exemplary embodiment, the height 42 may beselected based on a height of the first pallet 14. For example, theheight 42 may be selected to be less than the height of the first pallet14. In an exemplary embodiment, the height 42 may be selected in a rangeof 3-5 inches, such as 4 inches, for example. The first back stop 24also includes a first attachment member 44 that extends downward fromthe first horizontal member 30 by a length along the inner surface 68 ofthe side 60 of the first rack 16 to attach the first back stop 24 to thefirst rack 16. In an exemplary embodiment, the length of the firstattachment member 44 may be selected in a range of 1-2 inches, such as 1inch, for example.

As illustrated in FIG. 5, the double back stop 22 also includes thesecond back stop 26 discussed above which includes a second horizontalmember 32 configured to extend across a top of the second rack 20. Thesecond back stop 26 also includes a second back stop member 40 to extendupward from the second horizontal member 32 by a height 42 to preventlateral movement of the second pallet 18 beyond the second back stop 26.As with the first back stop member 38, the height 42 of the second backstop member 40 may be selected based on a height of the second pallet18. For example, the height 42 may be selected to be less than theheight of the second pallet 18. In an exemplary embodiment, the height42 may be selected within a range of 3-5 inches, such as 4 inches, forexample. The second back stop 26 also includes a second attachmentmember 46 that extends downward from the second horizontal member 32 bya length along the inner surface 68 of the side 60 of the second rack 20to attach the second back stop 26 to the second rack 20.

FIG. 5 further illustrates that the first attachment member 44 includesa hole 43 47 configured to pass a fastener (not shown) through the firstattachment member 44 and the first rack 16, in order to attach the firstback stop 24 to the first rack 16. Similarly, the second attachmentmember 46 includes a hole 43 47 configured to pass a fastener throughthe second attachment member 46 and the second rack 20, in order toattach the second back stop 26 to the second rack 20. After the firstand second attachment members 44, 46 are extended along the innersurface 68 of the side 60 of the first and second racks 16, 20, thefastener is passed through the holes 43 and into the inner surface 68,to secure the first and second back stops 24, 26 to the first and secondracks 16, 20. In an exemplary embodiment, the holes 43 47 may have adiameter in a range of ⅛-½ inches, such as ¼ inches for example.

FIG. 5 further illustrates that the double back stop 22 includes themiddle section 28 with a horizontal cross-member 29 that interconnectsthe first back stop member 38 with the second back stop member 40 alonga top of the first back stop member 38 and a top of the second back stopmember 40. As illustrated in FIG. 5, the length of the horizontalcross-member 29 is the minimum distance 25. Additionally, as illustratedin FIG. 5, the middle section 28 includes a vertical cross-member 35that interconnects the first back stop member 38 to the second back stopmember 40 along a center 37 of a width of the first and second back stopmembers 38, 40. Although the embodiment of the vertical cross-member 35depicted in FIG. 5 interconnects the first and second back stop members38, 40 along the center 37 of their width, the embodiments of thepresent invention may position the vertical cross-member 35 tointerconnect the first and second back stop members 38, 40 at any regionalong a width of the first and second back stop members 38, 40. In anexemplary embodiment, the vertical cross-member 35 enhances thestructural integrity of the double back stop 22 in the presence oflateral loads imposed by the first and second pallets 14, 18 against thefirst and second back stop members 38, 40. In an exemplary embodiment,when the vertical cross-member 35 is integrally connected to the doubleback stop 22 other than with a welding operation, the verticalcross-member 35 enhances the structural integrity of the double backstop 22, to withstand up to 3000 pounds of lateral force imposed by thefirst and second pallets 14, 18 on the first and second back stopmembers 38, 40. In another exemplary embodiment, when the verticalcross-member 35 is integrally connected to the double back stop 22 witha welding operation, the structural integrity of the double back stop 22is enhanced to withstand up to 4900 pounds of lateral force imposed bythe first and second pallets 14, 18 on the first and second back stopmembers 38, 40. These numerical force thresholds are merely exemplaryand the embodiments of the present invention are not limited to thesethresholds and the double back stop may be designed to withstand greaterforce threshold of the lateral loads imposed by the first and secondracks on the double back stop.

As illustrated in FIG. 5, a length 52 of the double back stop 22 is asum of a length 48 of the first horizontal member 30, a length 50 of thesecond horizontal member 32 and the minimum distance 25 length of themiddle section 28. As previously discussed, in an exemplary embodiment,the minimum distance 25 is the minimum separation 12. In one exemplaryembodiment, the length 48, 50 of each of the first and second horizontalmembers 30, 32 is one half of the difference between the length 52 ofthe double back stop 22 and the minimum separation 12. In anotherexemplary embodiment, the length 48, 50 of each of the first and secondhorizontal members 30, 32 is in a range of 4-6 inches, such as 5 inches,for example. As further illustrated in FIG. 2, the first and secondhorizontal members 30, 32 each include a rack overhang portion 54 thatextends over the side 60 of the rack 16, 20 to attach the double backstop 22 to the racks 16, 20. Additionally, as illustrated in FIG. 2, thefirst and second horizontal members 30, 32 each include a palletoverhang portion 56 that vertically supports the first and secondpallets 14, 18 between the first and second racks 16, 20.

In one embodiment of the present invention, the first and second backstop members 38, 40 and the horizontal cross-member 29 are made from anintegral piece of material, such as an integral piece of steel material,for example. The vertical cross-member 35 is integrally connected to theintegral piece of material, such as with a welding operation, forexample. FIG. 3 depicts the welding joint 27 between the verticalcross-member 35 and the first and second back stop members 38, 40 andthe horizontal cross-member 29. As illustrated in FIG. 5, to form thedouble back stop 22, the integral piece of material is bent along afirst line 31, to form the first back stop member 38 and is bent along asecond line 33, to form the second back stop member 40. The integralpiece of material is then bent along a third line 39, to form the firsthorizontal member 30 and is bent along a fourth line 41, to form thesecond horizontal member 32. The integral piece of material is then bentalong a fifth line 43, to form the first attachment member 44 and isbent along a sixth line 45, to form the second attachment member 46. Thelines 31, 33, 39, 41, 43, 45 are spaced apart along the integral pieceof material, based on the desired lengths of each of the parts of thedouble back stop 22. For example, the first and second lines 31, 33 arespaced apart by the minimum separation 12, so that the minimum distance25 length of the middle section 28 is the minimum separation 12. In anexemplary embodiment, the integral piece of material is bent atapproximate orthogonal angles along each of the lines 31, 33, 39, 41,43, 45, as depicted in FIG. 5. In another exemplary embodiment, theintegral piece of material may have a length in a range of 14-17 inches,a width in a range of 2-4 inches and a thickness in a range of 1/16-¼inches, for example.

FIGS. 6-8 illustrate additional views of the double back stop 22 fromdifferent angular perspectives, with the structural features previouslydiscussed.

FIG. 9 illustrates an alternate embodiment of the double back stop 22′that can be used to maintain the minimum separation 12 between thepallets 14, 18 in the system 10 of FIGS. 2-3. The double back stop 22′includes the middle section 28′ that connects the first back stop 24′ tothe second back stop 26′ with a vertical cross-member 35′ with end 37′and without a horizontal cross-member. As with the middle section 28 ofFIG. 5, the length of the middle section 28′ is the minimum distance 25.In an exemplary embodiment, the minimum distance 25 is the minimumseparation 12 required to be maintained between the pallets 14, 18.Unlike the double back stop 22 of FIG. 5, the first back stop 24′, thesecond back stop 26′ and the middle section 28′ are not formed frombending an integral piece of material at spaced apart locations.Instead, the middle section 28′ is integrally connected to each of thefirst back stop 24′ and the second back stop 26, such as with a weldingoperation, for example.

FIG. 10 illustrates a flowchart depicting a method 100 for forming thedouble back stop 22 to maintain the minimum separation 12 between thefirst pallet 14 positioned on the first rack 16 and the second pallet 18positioned on the second rack 20. The method 100 starts at 101 byproviding 102 an integral piece of material. The method 100 thenincludes bending 104 the integral piece of material at the first line 31to form the first back stop member 38 to prevent lateral movement of thefirst pallet 14 beyond the first back stop member 38, when the firstpallet 14 engages the first back stop member 38. The method 100 theninvolves bending 106 the integral piece of material at the second line33 spaced from the first line 31 by the minimum separation 12 to formthe second back stop member 40 to prevent lateral movement of the secondpallet 18 beyond the second back stop member 40 when the second pallet18 engages the second back stop member 40. Additionally, the bending 106step is performed, to form the horizontal cross member 29 extending theminimum distance 25 between the first back stop member 38 and the secondback stop member 40. In an exemplary embodiment, the minimum distance 25is the minimum separation 12. The method 100 may also include integrallyconnecting 108 the vertical cross-member 35 to the first back stopmember 38, the second back stop member 40 and the horizontal crossmember 29 along a region of a width of the first back stop member 38 andthe second back stop member 40, such as the center 37 of the width,before the method 100 ends at 109.

FIG. 11 illustrates a flowchart depicting a method 200 200′ formaintaining the minimum separation 12 between the first pallet 14positioned on the first rack 16 and the second pallet 18 positioned onthe second rack 20. The method 200 200′ begins at 201 201′ by providing202 202′ the double back stop 22 including the first back stop 24, thesecond back stop 26 and the middle section 28 connecting the first backstop 24 to the second back stop 26 such that the first back stop 24 andthe second back stop 26 are spaced apart by the minimum distance 25 asdetermined by the middle section 28. The method 200 200′ furtherincludes attaching 204 204′ the first back stop 24 to the first rack 16and the second back stop 26 to the second rack 20. The method 200 200′further includes positioning 206 206′ the first pallet 14 on the firstrack 16 and the second pallet 18 on the second rack 20. The method 200200′ further includes inhibiting lateral movement 208 208′ of the firstpallet 14 beyond the first back stop 24 and the second pallet 18 beyondthe second back stop 26 such that the minimum separation 12 ismaintained between the first pallet 14 and the second pallet 18, beforethe method 200 200′ ends at 209 209′.

FIGS. 12-14 illustrate another alternate embodiment of the invention,double back stop 22″. Double back stop 22″ includes clips 200. Clips 200are affixed (e.g., welded) to the double back stop 22″ and are spacedfrom attachment members 44 and 46 to form a channel 202. The channel 202is sufficiently wide for receipt therein of racks 16 and 18. Double backstop 22″ may be affixed (e.g., via bolt or screw 88) to racks 16 and/or18. Clip 200 may a L-shaped channel member of a flat member.

FIG. 15 illustrates another alternate embodiment of the invention,double back stop 22″′. Double back stop 22″′ includes a web 300. Web 300may be integral with vertical cross member 35, or added to verticalcross member 35, or added to the double back stop separately from thevertical cross member 35. Web 300 is affixed (e.g., welded) to doubleback stop 22″′. Web 300 may extend between (or span the space between)attachment members 44 and 46 or may extend only a portion of thedistance between attachment members 44 and 46 or may extend betweenclips 200. The height (top to bottom) of web 300 may be any heightsufficient to add additional lateral strength to the double back stop.The thickness, top to bottom, (or width) of web 300 may be sufficient toadd additional lateral strength to the double back stop.

FIG. 16 illustrates another alternate embodiment of the invention,double back stop 22″″. Double back stop 22″″ combines clips 200 and web300. Member 400, combined clip 200 and web 300, has bent terminal ends402. The bent terminal ends 402 define, in part channel 202. Member 400may be integral with vertical cross member 35, or added to verticalcross member 35, or added to the double back stop separately from thevertical cross member 35. Member 400 is affixed (e.g., welded) to doubleback stop 22″″. The height (top to bottom) of member 400 may be anyheight sufficient to add additional lateral strength to the double backstop. The thickness, top to bottom, (or width) of member 400 may besufficient to add additional lateral strength to the double back stop.

FIG. 17 illustrates another alternate embodiment of the invention,double back stop 22″″′. Double back stop 22″″′ includes slots 500. Slots500 are formed in the double back stop so that element (i.e., wires) ofgrating 58 may fit into slots 500 and the double back stop may sit flush(or flat) on the racks 16 and 18. Slots 500 extend from any point onhorizontal members 30 and 32 (e.g., mid-point on the horizontal members,but not so limited) to the terminal ends of the attachment members 44and 46.

The double back stop may include any combination of the clip 200 formingthe channel 202, web 300, member 400 and slot 500.

This written description uses examples to disclose embodiments of theinvention, including the best mode, and also to enable any personskilled in the art to make and use the embodiments of the invention. Thepatentable scope of the embodiments of the invention is defined by theclaims, and may include other examples that occur to those skilled inthe art. Such other examples are intended to be within the scope of theclaims if they have structural elements that do not differ from theliteral language of the claims, or if they include equivalent structuralelements with insubstantial differences from the literal languages ofthe claims.

That which is claimed is:
 1. A system for maintaining a minimumseparation between a first pallet positioned on a first rack and asecond pallet positioned on a second rack, said system comprising: adouble back stop including; a first back stop configured to attach tothe first rack and to prevent lateral movement of the first palletbeyond the first back stop; a second back stop configured to attach tothe second rack and to prevent lateral movement of the second palletbeyond the second back stop such that the minimum separation ismaintained between the first and second pallets; and a middle section toconnect the first back stop to the second back stop to maintain aminimum distance between the first back stop and the second back stopsuch that the minimum separation is maintained between the first andsecond pallets, the middle section includes a horizontal cross-memberinterconnection interconnecting the first back stop member with thesecond backstop member along a top of the first and second back stopmember stops and a vertical cross-member, the vertical cross-member is avertical plate that is welded along a center of the first back stopmember, the second back stop member, and the middle section, the doubleback stop withstands lateral forces in the range of 3000 to 4900 pounds;and an element consisting of one or more of the following: a clipforming a channel affixed to the double back stop, and/or a web affixedto the double back stop, and/or a member affixed to the double backstop, and/or a slot in the double back stop.
 2. The system of claim 1wherein the element consists of the clip forming the channel.
 3. Thesystem of claim 1 wherein the element consists of the web affixed to thedouble back stop.
 4. The system of claim 1 wherein the element consistsof the member affixed to the double back stop.
 5. The system of claim 1wherein the element consists of the slot in the double back stop.
 6. Thesystem of claim 1 wherein the element consists of the clip forming thechannel, and the web affixed to the double back stop, and the slot inthe double back stop.
 7. The system of claim 1 wherein the elementconsists of the member affixed to the double back stop, and the slot inthe double back stop.